Direct Liquid-Cooled Inductor Housing for Stationary Thermal Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing cooling methods for inductor assemblies in vehicle power converters, such as indirect liquid cooling and direct liquid cooling using transmission fluid, are inadequate, particularly when the vehicle is stationary or not circulating fluid, leading to limited cooling efficiency and potential thermal management issues.
Innovation Solution
A housing system with first and second housing members that encapsulate the inductor assembly's winding and core, featuring inlets and outlets connected to a fluid system to circulate pressurized fluid for enhanced convective and conductive heat transfer, ensuring effective thermal management by maintaining direct fluid contact with the inductor assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If indirect liquid cooling is used by placing the inductor assembly in a housing surrounded by potting material and thermally connecting to a cooling plate, then the inductor assembly is protected and cooled via conductive and convective heat loss, but the cooling efficiency is reduced and the structure becomes more complex
Solution Approach 1:
The patent removes the potting material and cooling plate from the cooling system, extracting the unnecessary components that added complexity. The inductor assembly is directly exposed to the circulating fluid, eliminating the intermediate thermal connection layers while maintaining protection through the housing structure alone.
Solution Approach 2:
The patent eliminates the potting material as an intermediary thermal connection medium. Instead, the cooling fluid directly contacts the inductor assembly, removing the intermediate layer that hindered heat transfer efficiency while the housing provides the necessary structural protection.
2Device complexity
If direct liquid cooling is used by positioning an uncovered inductor assembly within a transmission case where transmission fluid can splash onto it, then the cooling structure is simplified, but cooling efficiency is limited when the vehicle is stationary or transmission fluid is not circulating
Solution Approach 1:
The patent introduces a pump-driven fluid circulation system that dynamically adapts to different vehicle operating conditions. The pump ensures continuous fluid flow through the housing regardless of vehicle motion, transforming the static splash-cooling approach into an active, controllable circulation system that maintains reliable cooling in all conditions.
Solution Approach 2:
The cooling system uses the vehicle's existing transmission fluid and pump infrastructure to serve the cooling function, eliminating the need for a separate cooling system. The fluid circulation is self-regulated through the housing's inlet and outlet connections to the transmission case.
3Temperature
If the inductor assembly is encapsulated in a housing with fluid circulation, then direct fluid contact improves heat transfer, but the housing design becomes more complex with multiple inlets and outlets
Solution Approach 1:
The housing serves multiple functions simultaneously: it provides structural protection for the inductor assembly, creates direct fluid contact surfaces for heat transfer, and incorporates inlet/outlet ports for fluid circulation. This multi-functionality reduces the need for separate cooling components while achieving effective thermal management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides improved heat dissipation and thermal management for the inductor assembly, enhancing its performance and efficiency by maintaining direct fluid contact and optimizing heat transfer pathways, even when the vehicle is stationary or transmission fluid is not circulating.
Implementation Method 1
convective heat loss to the circulating fluid
Implementation Method 2
conductive heat loss to the cooling plate
Data Source
AI summary
A vehicle, a vehicle electronics power assembly, and a method for providing and cooling an inductor assembly are provided. The vehicle has provided with a vehicle electrical system with a variable voltage converter (VVC) and an inductor assembly with a core and a winding. A housing is provided with a first housing member and a second housing member. The first and second housing members cooperate to encapsulate the winding and at least a portion of the core of the inductor assembly. The first housing member defines a first inlet and a first outlet, and the second housing member defines a second inlet and a second outlet. A fluid system is connected to the first inlet, the second inlet, the first outlet, and the second outlet to provide pressurized fluid to the first and second inlets to circulate fluid through the housing.